Electric glory hole furnace assembly

ABSTRACT

An electric glass hot shop system is described herein that has at least one electrically powered heating unit (e.g., electric furnace, electric glory hole, electric pipe warmer, electric color box, electric annealer, electric crucible kiln) used in the processing of glass.

CLAIMING BENEFIT OF PRIOR FILED U.S. APPLICATION

This is a divisional of U.S. patent application Ser. No. 12/603,167entitled “Electric Glass Hot Shop System” filed on Oct. 21, 2009, nowpending, the content of which is relied upon and incorporated herein byreference in its entirety.

TECHNICAL FIELD

The present invention relates to an electric glass hot shop system thathas at least one electrically powered heating unit (e.g., electricfurnace, electric glory hole, electric pipe warmer, electric color box,electric annealer, electric crucible kiln) used in the processing ofglass.

BACKGROUND

Extremely high temperatures are required to enable the melting,processing and forming of glass. In typical glass forming operationsthis high temperature requirement extends to the initial melting of theglass in a furnace, the periodic re-heating of the glass in a gloryhole, the heating of the glass while applying colored additives in acolor box, the pre-heating of a glass manipulating pipe in a pipewarmer, and the annealing of formed glass in an annealer. Generally,glass working equipment uses natural gas or propane fueled flames asheat sources to melt, process and form the glass. However, there aresome situations or venues where a gas source is not readily available,or where the use of a gas source is excluded for safety reasons. Forinstance, one such situation or venue where a gas source is prohibitedfor safety reasons is on a cruise ship where it would be desirable to beable to perform hot glass forming shows for people vacationing on thecruise ship.

In these situations or venues, electrically heated glass workingequipment are alternatives to the glass working equipment that use a gassource. The electrically heated glass working equipment utilizeelectrically resistive heating elements such as, for example, molybdenumdisilicide to generate radiative heat. Unfortunately, electricity istypically a poor means of supplying bulk energy to glass workingequipment. For instance, a typical glass furnace of about 150 lbscapacity would have to be supplied with a 400,000 BTU burner, which isthe equivalent of approximately 115 KW of electrical power. However, 115KW power supplies are generally much too expensive and bulky to beconsidered as a useful source of energy for such a small glass furnace.In contrast, power supplies of <35 KW are economically feasible and canbe a useful source of energy for a glass furnace if a more efficientinsulation package is provided and the glass is allowed a longer periodof time to melt and fine out. There are several types of electricallyheated glass furnaces currently available today on the market, which uselow energy inputs, but they have their own problems and they oftenintroduce design features that limit their usefulness. These problemsand other problems associated with other types of glass workingequipment are discussed below.

Furnace

-   -   Existing door systems have tracks and wheels which fail to        create a tight seal and are prone to energy leakage.        Furthermore, existing rear hinge designs eliminate easy access        to heating elements in the top of the furnace    -   The heating elements are mounted in the top (crown) of the        furnace, which means that the heating elements and corresponding        electrical supplies must be removed to be able to access and        service the crucible.

Glory Hole (GH)

-   -   Existing door systems are difficult to maintain and have        undesirable energy leakage.    -   There are few electric glory hole's commercially available.        Perhaps one reason for this is that heating elements are located        in a position that creates a potential for contact with glass        which if this occurred it would render the heating elements        useless. Another possible reason is that electric heat elements        provide mostly radiant heat with very little convection energy        like gas fired glory holes and as a result there would be        undesirable hot spots in the walls next to the heating element        holders.

Combination Pipe Warmer and Color Box

-   -   There are no electrically heated pipe warmers commercially        available.

Annealer

-   -   Existing annealer door seals fail due to their exposure to heat        and abrasion during the loading and unloading of the annealer.

Annealer's Crucible Kiln

-   -   Existing door is too large and when it is opened to much heat        escapes.

Thus, any enhancement of the traditional glass working equipment and inparticular the electrical glass working equipment would help improve themelting, processing and forming of glass.

SUMMARY

In one aspect, the present invention provides an electric glass hot shopsystem for processing glass that includes: (a) an electric furnace; (b)an electric glory hole; (c) an electric pipe warmer; (d) an electriccolor box; (e) an electric annealer; and (f) an electric crucible kiln.The electric glass hot shop system is well suited to be used in a venueor situation where a gas source is prohibited to be used for safetyreasons like on a cruise ship.

In another aspect, the present invention provides an electric glory holefor processing glass. In one example, the electric glory hole includes:(a) a body with a first opening located therein; and (b) a door systemincluding a first door which is hung over the first opening in the body,where the first door has a first hinged side and a second hinged side,where the first hinged side has a first frame that receives and supportsat least one cast block, and where the second hinged side has a secondframe that receives and supports at least one cast block. The doorsystem may further include: (a) a second door which has a first hingedside and a second hinged side, where the first hinged side has a firstframe that receives and supports at least one cast block, and where thesecond hinged side has a second frame that receives and supports atleast one cast block; (b) a third door which has a first hinged side anda second hinged side, where the first hinged side has a first frame thatreceives and supports at least one cast block, and where the secondhinged side has a second frame that receives and supports at least onecast block; and (c) the first door is hung over the first opening on thebody, and the second door is hung on the first door, and the third dooris hung on the second door. The electric glory hole may also include aspecially designed refractory element baffle which is located within thebody, where each refractory element baffle includes a block with apassage through which an heating element is inserted and a cavity inwhich hangs the heating element, where the cavity is larger than theheating element, and where the cavity is sized to encompass at leastthree sides of the heating element. Furthermore, the electric glory holemay have one or more specially designed insulation packages which helpto maintain a desired temperature within the body.

In yet another aspect, the present invention provides an electricfurnace for processing glass. In one example, the electric furnaceincludes: (a) a crucible unit; and (b) a heating unit, coupled to thecrucible unit, where the heating unit has an opening formed therein anda door attached to a cantilevered arm which has a hinge connected to atleast an outer portion of the heating unit, where the cantilevered armrotates on the hinge such that the door is moved to cover the openingand prevent access to an interior of the heating unit and the crucibleor the door is moved away from the opening to allow access to theinterior of the heating unit and the crucible. The heating unit mayfurther include a crown suspension system located therein which supportsat least one heating element, where the crown suspension system includesa ring of locking bricks that support a crown casting which thensupports the at least one heating element. Furthermore, the electricfurnace may have one or more specially designed insulation packageswhich help to maintain a desired temperature within the crucible and theheating unit.

Additional aspects of the invention will be set forth, in part, in thedetailed description, figures and any claims which follow, and in partwill be derived from the detailed description, or can be learned bypractice of the invention. It is to be understood that both theforegoing general description and the following detailed description areexemplary and explanatory only and are not restrictive of the inventionas disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be had byreference to the following detailed description when taken inconjunction with the accompanying drawings wherein:

FIG. 1 is a block diagram of an exemplary electric glass hot shop systemwhich includes an electric furnace, an electric glory hole, an electricpipe warmer, an electric color box, an electric annealer, and anelectric crucible kiln in accordance with an embodiment of the presentinvention;

FIGS. 2A-2G are different diagrams illustrating in greater detail theexemplary electric furnace shown in FIG. 1 in accordance with anembodiment of the present invention;

FIGS. 3A-3M are different diagrams illustrating in greater detail theexemplary electric glory hole shown in FIG. 1 in accordance with anembodiment of the present invention;

FIGS. 4A-4B are different diagrams illustrating in greater detail theexemplary electric pipe warmer and the exemplary electric color boxshown in FIG. 1 in accordance with an embodiment of the presentinvention;

FIGS. 5A-5G are different diagrams illustrating in greater detail theexemplary electric annealer shown in FIG. 1 in accordance with anembodiment of the present invention; and

FIGS. 6A-6D are different diagrams illustrating in greater detail theexemplary electric crucible kiln shown in FIG. 1 in accordance with anembodiment of the present invention.

DETAILED DESCRIPTION

Referring to FIG. 1, there is shown a block diagram of an exemplaryelectric glass hot shop system 100 in accordance with an embodiment ofthe present invention. In this example, the electric glass hot shopsystem 100 includes an electric furnace 102, an electric glory hole 104,an electric pipe warmer 106, an electric color box 108, an electricannealer 110, and an electric crucible kiln 112. The electric glass hotshop system 100 further includes a power supply 114 (e.g., ≦35 KW powersupply 114) that supplies electricity to the electric furnace 102, theelectric glory hole 104, the electric pipe warmer 106, the electriccolor box 108, the electric annealer 110, and the electric crucible kiln112. Typically, the electric furnace 102 is used to melt batch materialsto form a molten glass. The electric glory hole 104 is used toperiodically re-heat the molten glass while a pipe is used to hold andmanipulate the molten glass to form the desired glass shape. Theelectric pipe warmer 106 is used to pre-heat the pipe. The electriccolor box 108 is used to apply colored additives to the molten glassduring the forming process. The electric annealer 110 is used to annealthe formed glass. The electric crucible kiln 112 which is placed underthe electric annealer 110 is used to melt small quantities of glass andcolored fits, usually less then 50 lbs. Each piece of electric glassworking equipment 102, 104, 106, 108, 110 and 112 is considered to be anindividual component that can stand and function alone rather thanhaving to be part of the entire electric glass hot shop system 100. Eachelectric glass working equipment 102, 104, 106, 108, 110 and 112 isdiscussed and described in greater detail below with respect to FIGS.2-6.

Referring to FIGS. 2A-2G, there are different diagrams illustrating ingreater detail the exemplary electric furnace 102 in accordance with anembodiment of the present invention. The electric furnace 102 includes acrucible unit 202, a heating unit 204, and an electrical control box 206(see FIGS. 2A-2B). The crucible unit 202 is where the batch materialsare placed and then melted to form the molten glass (not shown). Thecrucible unit 202 is attached to the heating unit 204 in a manner thatmakes it easy to drop and move the crucible unit 202 out of the way whenone needs to perform maintenance on the heating unit 204. Also, thecrucible unit 202 can be easily dropped and removed from the heatingunit 204 so a new crucible unit 202 can be quickly connected to theheating unit 204. The electrical control box 206 supplies the requiredelectricity to one or more heating elements 208 which are located withinthe heating unit 204. The electric furnace 102 includes other componentsbut only the components like a crown suspension system 210, atorsion-box door system 212, and specially designed insulation packages214 a, 214 b and 214 c which are relevant to the present discussion aredescribed in detail below.

As shown in FIG. 2B, the heating unit 204 incorporates the crownsuspension system 210 which has a crown 216 that supports the heatingelements 208 in a manner that allows the crucible unit 202 to beserviced without having to remove the crucible unit 202 from the heatingunit 204. The crown suspension system 210 includes a cast tube 218(outer body of furnace 102) which has a rabbit 220 on the bottom edgethereof is configured to receive a ring of locking bricks 222. Thelocking bricks 222 are arranged between the cast tube 218 and a crowncasting 224. The locking bricks 222 prevent the crown 216 (which issupported by the crown casting 224) from falling down and also transferthe weight of the crown casting 224 to a lower outside ring 226 on theheating unit 204. The ring of locking bricks 222 is suspended andcantilevered in a way that leaves a clear space under the crown 216 toprovide access to the crucible unit 102. The crown suspension system 210greatly reduces the amount of down time required to change the crucibleunit 102 and eliminates need for removing electrical components duringservice.

As shown in FIGS. 2A-2D, the heating unit 204 includes the torsion boxdoor system 212 which has a door 228 attached to a cantilevered arm 230in a manner that allows the door 228 to be adjusted in-and-out,up-and-down, as well as sideways. The cantilevered arm 230 has a hinge232 which is connected to a body 234 of the heating unit 204. Thecantilevered arm 230 rotates on the hinge 232 over a central axis toallow the door 228 to be moved to cover an opening in the heating unit204 or to allow the door 228 to be moved away from the opening in theheating unit 204. The door system 212 makes it easy to change thecrucible unit 202 and allow unobstructed access to the heating elements208. The door system 212 is a marked-improvement over the traditionaldoor systems that utilize tracks and wheels which fail to create a tightseal and are prone to energy leakage. Plus, the door system 212 is amarked-improvement over the traditional rear-hinge door systems whichprevent easy access to the heating elements 208 located in the top ofthe furnace unit 204.

As shown in FIGS. 2B and 2E-2G, the crucible unit 202 and the heatingelement 204 incorporate specially designed insulation packages 214 a,214 b and 214 c that help to prevent the interior of the electricfurnace 102 from becoming too cold or too hot during the meltingoperation. In this example, the electric furnace 102 would normally havean internal operating temperature in a range of about 1120° C. to 1250°C. In FIG. 2E, the crucible unit 202 is shown to have a furnace cruciblefloor 236 which is made from an outer panel 238 and a specially designedinsulation package 214 a. In this example, the specially designedinsulation package 214 a includes a microporus panel 240 (approximately1″ thick) located next to the outer panel 238, a fire brick 242(approximately 2½″ thick) located next to the microporus panel 240, alow cement castable layer 244 (e.g., 1½″ thick intracast MZ 244) locatednext to the fire brick 242, and a crucible material 246 (e.g., 1 ½″thick cast mullite 246) located next to the low cement castable layer244. The crucible material 246 has an outer face 248 which is exposed tothe heat.

In FIG. 2F, the crucible unit 202 is shown to have a furnace cruciblewall 250 which is made from an outer panel 252 and a specially designedinsulation package 214 b. In this example, the specially designedinsulation package 214 b includes a microporus panel 254 (approximately½″ thick) located next to the outer panel 252, a ceramic fiber layer 256(e.g., 1½″ thick HP fiber frax 256) located next to the microporus panel254, a fire brick 258 (approximately 2½″ thick) located next the ceramicfiber layer 256, a low cement castable layer 260 (e.g., 2″ thickintracast MZ 260) located next to the fire brick 258, and a cruciblematerial 262 (e.g., 2″ thick cast mullite 262) located next to the lowcement castable layer 260. The crucible material 262 has an outer face264 which is exposed to the heat.

In FIG. 2G, the heating unit 204 is shown to have a furnace crown wall266 which is made from an outer panel 268 and a specially designedinsulation package 214 c. In this example, the specially designedinsulation package 214 c includes a microporus panel 270 (approximately½″ thick) located next to the outer panel 268, a ceramic fiber layer 272(e.g., 3″ thick HP fiber frax 272) located next to the microporus panel270, and a low cement castable layer 274 (e.g., 2½″ thick intracast MZ274) located next to the ceramic fiber layer 272. The low cementcastable layer 274 has an outer face 276 which is exposed to the heat.

Referring to FIGS. 3A-3M, there are several different diagramsillustrating in greater detail the exemplary electric glory hole 104 inaccordance with an embodiment of the present invention. The electricglory hole 104 is mounted on a structure 301 and includes a body 302with an opening 304 through which a pipe holding molten glass can beinserted and then manipulated to form the desired glass shape (see FIGS.3A-3D). The electric glory hole 104 includes an electrical control box306 which supplies the required electricity to one or more heatingelements 308 (see FIGS. 3A-3D). The electric glory hole 104 includesother components but only the components like a specially designed doorsystem 310, specially designed refractory element baffles 312, a videocamera 314 and specially designed insulation packages 316 a, 316 b and316 c which are relevant to the present discussion are described indetail below.

As shown in FIGS. 3A-3F, the electric glory hole 104 includes thespecially designed door system 310 which has three doors 318, 320 and322 where the first door 318 is hung upon the body 302 and at leastpartially covers the opening 304, the second door 320 is hung upon thefirst door 318, and the third door 322 is hung upon the second door 320.The first door 318 is larger than the second door 320 which in turn islarger than the third door 322. In this example, the first door 318 hasa first hinged side 324 a and a second hinged side 324 b, where thefirst hinged side 324 a has a first frame 326 a that receives andsupports one or more cast blocks 328 a and 328 a′ (two shown) and thesecond hinged side 324 b has a second frame 326 b that receives andsupports one or more cast blocks 328 b and 328 b′ (two shown)(see FIGS.3E-3F). The second door 320 has a first hinged side 330 a and a secondhinged side 330 b, where the first hinged side 330 a has a first frame332 a that receives and supports one or more cast blocks 334 a and 334a′ (two shown) and the second hinged side 330 b has a second frame 332 bthat receives and supports one or more cast blocks 334 b and 334 b′.Likewise, the third door 322 has a first hinged side 336 a and a secondhinged side 336 b, where the first hinged side 336 a has a first frame338 a that receives and supports one or more cast blocks 340 a and 340a′ (two shown) and the second hinged side 336 b has a second frame 338 bthat receives and supports one or more cast blocks 340 b and 340 b′.

The doors 318, 320 and 322 can be easily kept in optimal condition andthus allow minimal energy loss since if any of the cast blocks 328 a,328 a′, 328 b, 328 b′, 334 a, 334 a′, 334 b, 334 b′, 340 a, 340 a′, 340b and 340 b′ have to be replaced then all one needs to do is remove thedamaged cast block from the frame 324 a, 324 b, 332 a, 332 b, 338 a and338 b and insert the new cast block. For instance, if the first door 318had a damaged cast block 328 a′ then one would remove pins 342 a and 342b from the first frame 326 a and slide-out the damaged cast block 328 a′(see FIGS. 3E and 3F). Then, the new cast block 328 a′ can be placed inthe first frame 326 a and the pins 342 a and 342 b re-inserted to holdthe new cast block 328 a′.

As shown in FIGS. 3B-3C and 3G, the electric glory hole 104 has a core344 which is sized and configured to enable a pipe holding molten glassto be inserted therein through the opening 304. The core 344 is formedfrom interconnected fire bricks 346 and a series of refractory elementbaffles 312. In FIG. 3H, there is shown a perspective view of exemplaryrefractory element baffle 312 that includes a block 350 which has apassage 352 located in a top thereof and a cavity 354 formed in a sidethereof. The passage 352 is sized to receive a heating element 308(e.g., molybdenum discilicide heating element 308) which is inserted atleast partially there through and the cavity 354 is sized to encompassand protect at least three sides of the heating element 308 (see FIGS.3B-3C). In particular, the refractory element baffle 312 has sides 358which protect the heating element 308 located and hanging within thecavity 354 such that when the pipe is inserted within the core 344 itwill not be able to touch and damage the heating element 308. Plus, therefractory element baffle 312 with the specially shaped cavity 354creates a high temperature shell around the heating element 308 thatreflects energy into the core 344. In one embodiment, the refractoryelement baffle 312 is cast from a 3000° F. dense refractory and thecavity 354 where the heating element 308 hangs is approximately ½″larger than the heating element 308. Plus, the heating element 308 wheninstalled is recessed about 1 inch from the inner edges of the cavity354. The refractory element baffle 312 solves the problem of having theheating element 308 to close to the pipe and helps to reduce thepotential damage to the heating element 308 as well as reduce thepotential hazard due to an electric shock and short circuit.

As shown in FIGS. 3B-3C and 3I-3J, the electric glory hole 104 has avideo camera 314 attached thereto so that it is isolated from the heatinside the core 344. The video camera 314 is used to demonstrate whattakes place inside the core 344 when the molten glass is re-heated onthe pipe. In this example, the video camera 314 connects to one side 367of a lens holder 362 which has another side 369 attached to a cameracasting 360 (see FIGS. 31 and 3J). The camera casting 360 is a castrefractory block that is located within an opening 364 in the body 302.The camera casting 360 has a tapered opening 366 in communication withthe core 344, where the tapered opening 366 is sized to allow adequatevisual inspection of the glory hole interior from behind the back wallof the body 302. The lens holder 362 includes a heat block seal 368 thathas a groove 370 which holds a lens 372 (e.g., 2″×2″ high temperaturequartz lens 372) followed by an air purge gap 374 (which is supplied gasfrom a gas purge system 376) which is followed by another groove 378within which is placed a glass filter lens 380. The quartz lens 372(located next to the video camera 314) prevents hot corrosive gaseslocated inside the core 344 from attacking the video camera 314. Theglass filter lens 380 (located next to the camera casting 360) shieldsthe video camera 314 from heat transferred from the lens 372. In oneexample, the video camera 358 would be mounted within 1″ of the glassfilter lens 380.

As shown in FIGS. 3B-3C and 3K-3M, the electric glory hole 104incorporates specially designed insulation packages 316 a, 316 b and 316c that help limit the temperature of the outer shell 382 to be less than225° F. In FIG. 3K, the electric glory hole 102 is shown to have a gloryhole element block wall 383 which is made from an outer panel 384 and aspecially designed insulation package 316 a. In this example, thespecially designed insulation package 316 a includes a microporus panel385 (approximately 1″ thick) located next to the outer panel 384, aceramic fiber layer 386 (e.g., 2″ thick HP fiber frax 386) located nextto the microporus panel 385, a low cement castable layer 387 (e.g., 2″thick intracast MZ 387) located next to the ceramic fiber layer 386. Thelow cement castable layer 387 has an outer face 388 which is exposed tothe heat.

In FIG. 3L, electric glory hole 102 is shown to have a glory hole wall389 which is made from an outer panel 390 and a specially designedinsulation package 316 b. In this example, the specially designedinsulation package 316 b includes a microporus panel 391 (approximately½″ thick) located next to the outer panel 390, a ceramic fiber layer 392(e.g., 1½″ thick HP fiber frax 392) located next to the microporus panel391, a fire brick 393 (approximately 2½″ thick) located next the ceramicfiber layer 392. The fire brick 393 has an outer face 394 which isexposed to the heat.

In FIG. 3M, electric glory hole 102 is shown to have a glory hole backwall 395 which is made from an outer panel 396 and a specially designedinsulation package 316 c. In this example, the specially designedinsulation package 316 c includes a microporus panel 397 (approximately½″ thick) located next to the outer panel 396, a ceramic fiber layer 398(e.g., 2½″ thick HP fiber frax 398) located next to the microporus panel397, a fire brick 399 (approximately 2½″ thick) located next the ceramicfiber layer 398. The fire brick 399 has an outer face 381 which isexposed to the heat.

Referring to FIGS. 4A-4B, there are several diagrams illustrating ingreater detail the exemplary electric pipe warmer 106 and the exemplaryelectric color box 108 in accordance with an embodiment of the presentinvention. The electric pipe warmer 106 is used to pre-heat the pipewhich is used to hold and manipulate the molten glass during the formingprocess. The electric color box 108 is used to apply colored additivesto the molten glass during the forming process. In this example, theelectric pipe warmer 106 and the electric color box 108 are both mountedon the same support unit 402 and are both supplied electricity from oneelectrical control box 404. The electric pipe warmer 106 includes a body406 with a pipe opening 408 formed therein and one or more heatingelements 410 located therein. The pipe opening 408 is sized andpositioned such that when a pipe is inserted therein the pipe will notbe able to contact the heating elements 410. In this example, the pipeopening 408 is located near the bottom of the body 406 and the heatingelements 410 are attached to the roof of the body 406. The heatingelements 410 are attached to the roof because glass sheds that fall offthe pipe during the heating process would damage the heating elements410 if they where located near the bottom or sides of the body 406. Theheating elements 410 can be nichrome elements which run throughprotective quartz tubes 412. The nichrome heating elements 410 canradiate at 2000° F. The electric pipe warmer 106 also includes aspecially designed insulation package 414 which includes fire bricks 416(e.g., 2300° F. fire bricks 416) which are coated with a high emissivitycoating 418 that is exposed to the heat and helps to increase the heattransfer into cold pipes. The fire bricks 416 are located next to aceramic fiber 420 (e.g., 1″ thick ceramic fiber 420) which is coatingthe internal portion of the body 406.

Referring to FIGS. 5A-5G, there are several diagrams illustrating ingreater detail the exemplary electric annealer 110 in accordance with anembodiment of the present invention. The electric annealer 110 is usedto anneal the formed glass. In this example, the electric annealer 110is mounted on a support unit 502 and is supplied electricity from anelectrical control box 504. The electric annealer 110 includes a body506 with an opening 508 formed therein which has a door system 510attached thereto which when opened provides access to the interior ofthe body 506 and when closed prevents access to the interior of the body506. The door system 510 includes a door 512, a frame 514, a gasket 516and a keeper 518, where the door 512 is attached to the frame 514 whichis attached to the gasket 516 which is attached to the keeper 518 whichis attached to the body 506 (see FIG. 5C). The configuration of the doorsystem 510 is desirable since the gasket 516 (e.g., tadpole silicagasket 516) is kept cool and has minimal exposure to abrasion because itis positioned between the frame 514 and the keeper 518. In addition, theelectric annealer 110 has one or more electrical heating elements 520located in the body 506 which radiate heat to anneal the formed glass.

As shown in FIGS. 5B and 5D-5G, the electric annealer 110 alsoincorporates specially designed insulation packages 522 a, 522 b, 522 cand 522 d. In FIG. 5D, the electric annealer 110 has an annealer wall524 which is made from an outer panel 526 and the specially designedinsulation package 522 a. In this example, the specially designedinsulation package 522 a includes a ceramic fiber layer 528 (e.g., 1″thick HP fiber frax 528) located next to the outer panel 526, and a firebrick 530 (approximately 2½″ thick) located next to the ceramic fiberlayer 528. The fire brick 530 has an outer face 532 which is exposed tothe heat.

In FIG. 5E, the electric annealer 110 has a floor 534 which is made froman outer panel 536 and the specially designed insulation package 522 b.In this example, the specially designed insulation package 522 bincludes a fiberglass silicate layer 538 (e.g., 2″ thick insblock 19538) located next to the outer panel 536, and a fire brick 540(approximately 2½″ thick) located next to the fiberglass silicate layer538. The fire brick 540 has an outer face 542 which is exposed to theheat.

In FIG. 5F, the electric annealer 110 has a ceiling 544 which is madefrom an outer panel 546 and the specially designed insulation package522 c. In this example, the specially designed insulation package 522 cincludes a microporus panel 548 (approximately ½″ thick) located next tothe outer panel 546, a ceramic fiber layer 550 (e.g., 2″ thick HP fiberfrax 550) located next to the microporus panel 548, and a thermalceramic layer 552 (e.g., 2″ thick M board 552) located next to theceramic fiber layer 550. The thermal ceramic layer 552 has an outer face554 which is exposed to the heat.

In FIG. 5G, the electric annealer 110 has the door 512 which is madefrom an outer panel 556 and the specially designed insulation package522 d. In this example, the specially designed insulation package 522 dincludes a microporus panel 558 (approximately ½″ thick) located next tothe outer panel 556, a ceramic fiber layer 560 (e.g., 2″ thick HP fiberfrax 560) located next to the microporus panel 558, and an thermalceramic layer 562 (e.g., 2″ thick M board 562) located next to theceramic fiber layer 560. The thermal ceramic layer 562 has an outer face564 which is exposed to the heat.

Referring to FIGS. 6A-6D, there are several diagrams illustrating ingreater detail the exemplary electric crucible kiln 112 in accordancewith an embodiment of the present invention. The electric crucible kiln112 is located below the electric annealer 110 and is used to melt smallquantities of glass and colored frits, usually less than 50 lbs. In thisexample, the electric crucible kiln 112 includes a crucible 602, a doorsystem 604 and an electrical control box 606 which supplies electricityto heating elements (not shown) located in the crucible 602. The doorsystem 604 includes a door 608 which is attached to a support arm 610which has a hinge 612 connected to the crucible 602. The support arm 610is arranged to rotate on the hinge 612 such that the door 608 can bemoved to cover an opening in the crucible 602 or the door 608 can bemoved away from the opening in the crucible 602. Alternatively, the doorsystem 604 if desired may be mounted on a side of the crucible 602rather than on top of the crucible 602 (as shown).

As shown in FIGS. 6B-6D, the crucible 602 also incorporates speciallydesigned insulation packages 614 a, 614 b, and 614 c. In FIG. 6B, thecrucible 602 has walls 616 which are made from an outer panel 618 andthe specially designed insulation package 614 a. In this example, thespecially designed insulation package 614 a includes a microporus panel620 (approximately 1″ thick) located next to the outer panel 618, aceramic fiber layer 622 (e.g., 1½″ thick HP fiber frax 622) located nextto the microporus panel 620, a fire brick 624 (approximately 2½″ thick)located next the ceramic fiber layer 622. The fire brick 624 has anouter face 626 which is exposed to the heat.

In FIG. 6C, the crucible 602 has a ceiling 628 which is made from anouter panel 630 and the specially designed insulation package 614 b. Inthis example, the specially designed insulation package 614 b includes amicroporus panel 632 (approximately 1″ thick) located next to the outerpanel 630, a ceramic fiber layer 634 (e.g., 1½″ thick HP fiber frax 634)located next to the microporus panel 632, a fire brick 636(approximately 2½″ thick) located next the ceramic fiber layer 634. Thefire brick 636 has an outer face 637 which is exposed to the heat.

In FIG. 6D, the crucible 602 has a floor 638 which is made from an outerpanel 640 and the specially designed insulation package 614 c. In thisexample, the specially designed insulation package 614 c includes amicroporus panel 642 (approximately 1½″ thick) located next to the outerpanel 640, a fire brick 644 (approximately 2½″ thick) located next themicroporus panel 642, a fiberglass silicate layer 646 (e.g., 1½″ thickinsblock 19 646) located next to the fire brick 644. The fiberglasssilicate layer 646 has an outer face 648 which is exposed to the heat.

Although one embodiment of the present invention has been illustrated inthe accompanying Drawings and described in the foregoing DetailedDescription, it should be understood that the invention is not limitedto the disclosed embodiment, but is capable of numerous rearrangements,modifications and substitutions without departing from the spirit of theinvention as set forth and defined by the following claims.

1-12. (canceled)
 13. An electric furnace for processing glass,comprising: a crucible unit; an electrical control box; and a heatingunit, coupled to the crucible unit and the electrical control box,wherein the heating unit has an opening formed therein and a doorattached to a cantilevered arm which has a hinge connected to at leastan outer portion of the heating unit, wherein the cantilevered armrotates on the hinge such that the door is moved to cover the openingand prevent access to an interior of the heating unit and the crucibleor the door is moved away from the opening to allow access to theinterior of the heating unit and the crucible.
 14. The electric furnaceof claim 13, wherein the crucible unit is located below the heatingunit.
 15. The electric furnace of claim 13, wherein the crucible unit islocated under the heating unit, and wherein the crucible unit and theheating unit are coupled to one another such that the crucible unit whenneeded is able to be decoupled from the heating unit so the crucibleunit is able to be moved away from the heating unit.
 16. The electricfurnace of claim 13, wherein said heating unit further comprises atleast one heating element and a crown suspension system, wherein thecrown suspension system comprises a ring of locking bricks and a crowncasting, wherein the ring of locking bricks are configured to supportthe crown casting, and wherein the crown casting is configured tosupport the at least one heating element.
 17. The electric furnace ofclaim 13, wherein the crucible further comprises: a floor whichcomprises a first outer panel and a first insulation package, whereinthe first insulation package comprises a first microporus panel locatednext to the first outer panel, a first fire brick located next to thefirst microporus panel, a first cement castable layer located next tothe first fire brick, and a first crucible material located next to thefirst cement castable layer; a wall which comprises a second outer paneland a second insulation package, wherein the second insulation packagecomprises a second microporus panel located next to the second outerpanel, a first ceramic fiber layer located next to the second microporuspanel, a second fire brick located next to the first ceramic fiberlayer, a second cement castable layer located next to the second firebrick, and a second crucible material located next to the second cementcastable layer; and the heating unit further comprises: a furnace crownwall which comprises a third outer panel and a third insulation package,wherein the third insulation package comprises a third microporus panellocated next to the third outer panel, a second ceramic fiber layerlocated next to the third microporus panel, and a third cement castablelayer located next to the second ceramic fiber layer.
 18. An electricfurnace for processing glass, comprising: a crucible unit; an electricalcontrol box; and a heating unit, coupled to the crucible unit and theelectrical control box, wherein said heating unit further comprises atleast one heating element and a crown suspension system, wherein thecrown suspension system comprises a ring of locking bricks and a crowncasting, wherein the ring of locking bricks are configured to supportthe crown casting, and wherein the crown casting is configured tosupport the at least one heating element.
 19. The electric furnace ofclaim 18, wherein the crucible unit is located below the heating unit.20. The electric furnace of claim 18, wherein the crucible unit islocated under the heating unit, and wherein the crucible unit and theheating unit are coupled to one another such that the crucible unit whenneeded is able to be decoupled from the heating unit so the crucibleunit is able to be moved away from the heating unit.
 21. The electricfurnace of claim 18, wherein the heating unit has an opening formedtherein and a door attached to a cantilevered arm which has a hingeconnected to at least an outer portion of the heating unit, wherein thecantilevered arm rotates on the hinge such that the door is moved tocover the opening and prevent access to an interior of the heating unitand the crucible or the door is moved away from the opening to allowaccess to the interior of the heating unit and the crucible.
 22. Theelectric furnace of claim 18, wherein the crucible further comprises: afloor which comprises a first outer panel and a first insulationpackage, wherein the first insulation package comprises a firstmicroporus panel located next to the first outer panel, a first firebrick located next to the first microporus panel, a first cementcastable layer located next to the first fire brick, and a firstcrucible material located next to the first cement castable layer; awall which comprises a second outer panel and a second insulationpackage, wherein the second insulation package comprises a secondmicroporus panel located next to the second outer panel, a first ceramicfiber layer located next to the second microporus panel, a second firebrick located next to the first ceramic fiber layer, a second cementcastable layer located next to the second fire brick, and a secondcrucible material located next to the second cement castable layer; andthe heating unit further comprises: a furnace crown wall which comprisesa third outer panel and a third insulation package, wherein the thirdinsulation package comprises a third microporus panel located next tothe third outer panel, a second ceramic fiber layer located next to thethird microporus panel, and a third cement castable layer located nextto the second ceramic fiber layer.
 23. An electric furnace forprocessing glass, comprising: a crucible unit; an electrical controlbox; and a heating unit, coupled to the crucible unit and the electricalcontrol box, wherein the heating unit further comprises a furnace crownwall which comprises a first outer panel and a first insulation package,wherein the first insulation package comprises a first microporus panellocated next to the first outer panel, a first ceramic fiber layerlocated next to the first microporus panel, and a first cement castablelayer located next to the first ceramic fiber layer; and wherein thecrucible further comprises: a floor which comprises a second outer paneland a second insulation package, wherein the second insulation packagecomprises a second microporus panel located next to the second outerpanel, a first fire brick located next to the second microporus panel, asecond cement castable layer located next to the first fire brick, and afirst crucible material located next to the second cement castablelayer; and a wall which comprises a third outer panel and a thirdinsulation package, wherein the third insulation package comprises athird microporus panel located next to the third outer panel, a secondceramic fiber layer located next to the third microporus panel, a secondfire brick located next to the second ceramic fiber layer, a thirdcement castable layer located next to the second fire brick, and asecond crucible material located next to the third cement castablelayer.
 24. The electric furnace of claim 23, wherein the crucible unitis located below the heating unit.
 25. The electric furnace of claim 23,wherein the crucible unit is located under the heating unit, and whereinthe crucible unit and the heating unit are coupled to one another suchthat the crucible unit when needed can be decoupled from the heatingunit so the crucible unit is able to be moved away from the heatingunit.
 26. The electric furnace of claim 23, wherein said heating unitfurther comprises at least one heating element and a crown suspensionsystem, wherein the crown suspension system comprises a ring of lockingbricks and a crown casting, wherein the ring of locking bricks areconfigured to support the crown casting, and wherein the crown castingis configured to support the at least one heating element.
 27. Theelectric furnace of claim 23, wherein the heating unit has an openingformed therein and a door attached to a cantilevered arm which has ahinge connected to at least an outer portion of the heating unit,wherein the cantilevered arm rotates on the hinge such that the door ismoved to cover the opening and prevent access to an interior of theheating unit and the crucible or the door is moved away from the openingto allow access to the interior of the heating unit and the crucible.